Traditional applications for metal injection molding (MIM) have been small (<25 gram) net shape parts exhibiting design and economic benefits over wrought or cast components. A new aqueous based binder system for MIM has been developed that offers the ability to produce large, thick parts in the range of 2 kg which are competitive with those produced by investment casting. Other significant advantages of this system are a clean and rapid debind and the ability to mold into soft tooling. As a result, savings are achieved not only by eliminating machining and other processing steps but also by reduced development and inventory costs. This technology is applied to a variety of consumer, automotive and industrial components, including aerospace components. Automotive applications include turbocharger, brake and ignition components as well as oxygen sensors. Primary materials are stainless steels and nickel based alloys. The technology is also applied to a wide range of other metal and ceramic systems.